Compactable furniture system

ABSTRACT

A compactable furniture system having a seat back with front and rear panels that are pivotally connected at the top of the front and rear panels and removably connected at the bottom of the front and rear panels with a pitch mechanism that fixes the seat back at a pitch angle during assembly.

BACKGROUND

Traditionally, large furniture seating items such as sofas, loveseats, chairs, and sleepers are fully constructed and assembled in a factory and then shipped, in the assembled state, to a desired destination, either a retailer or directly to a consumer. A major manufacturing cost for producing these items is the cost of shipping (i.e., freight costs). In addition, these bulky furniture items require a large amount of space to warehouse and store, which is also costly.

Furniture that can be manufactured and shipped, and then fully assembled by an end user, such as a retailer or consumer, is currently known. An example of such a furniture system can be found in U.S. Pat. No. 5,423,596. Disadvantageously, however, this furniture system has many components and assembly/disassembly of the finished product can be difficult for the end user.

In addition, many consumers live in homes or apartments that have narrow doors or stairways that cannot be navigated by traditional bulky furniture. This can require removing windows or doors, and/or hoisting large furniture items through upper story windows to place large furniture in these homes or apartments. Removing the furniture from the dwelling requires the same arduous process.

Therefore, there is a need for a furniture system that can be compacted into a small space for shipping, storage, and moving. It would also be advantageous if this furniture system can be easily assembled and disassembled by a retailer or consumer.

SUMMARY

According to the present invention, there is provided a compactable furniture system with a pitch mechanism that removably connects a front and rear panel of a seat back at a pitch angle. The compactable furniture system also has first and second side supports attached to the seat back and a front rail attached to the first and second side supports. A removable seat deck is disposed between the seat back, the front rail, and the first and second side supports.

The furniture system can additionally have a seat deck lock, which has a bracket, and a joining pin with a plate that can provide support for the seat deck. The furniture system can additionally have a center bar interposed between the rear panel and the front rail to provide support for the seat deck. A hinge lock can be used to join the front rail and the first and second side supports. The hinge lock can also have a hinge plate to provide support for the seat deck. Further, the furniture system can additionally have a set of legs that are attached to the first and second side supports.

In one embodiment, the pitch mechanism comprises a slotted bracket having one or more notches. The furniture system of claim 1 wherein the pitch mechanism comprises a bar with two apertures. The furniture system of claim 1 wherein the pitch mechanism comprises a bar with an aperture and a hook. The furniture system of claim 1 wherein the pitch mechanism comprises a locking joint. The furniture system of claim 1 wherein the front panel and the rear panel are pivotally connected with one or more hinges.

In another embodiment according to the present invention, there is provided a method for assembling compactable furniture. In one embodiment, a furniture system according to the present invention is selected. Then, the seat back and the front rail are attached to the first and second side supports. The pitch mechanism is then inserted into the seat back and the seat back is fixed a pitch angle. The seat deck is then inserted between the seat back, the front rail, and the first and second side supports. In a preferred embodiment, the furniture system additionally has a seat deck lock, and the seat deck lock is attached to at least one of the first side support, the second side support, or the front rail. In another preferred embodiment, the furniture system additionally has a hinge lock, at least one of the first and second side supports is attached to the front rail with the hinge lock.

FIGURES

These and other features, aspects and advantages of the present invention will become better understood from the following description, appended claims, and accompanying figures where:

FIG. 1 is a front side perspective view of a compactable furniture system, shown unassembled;

FIG. 2 is a front side perspective view of a compactable furniture system, shown partially assembled;

FIG. 3A is a front perspective view of a front seat deck lock;

FIG. 3B is a front perspective view of a side seat deck lock;

FIG. 4A is a front perspective view of a hinge lock, shown in an assembled form;

FIG. 4B is a front perspective view of a hinge lock, shown in an unassembled form;

FIG. 5A is an outer side perspective view of one embodiment of a pitch mechanism having a slide pitch lock;

FIG. 5B is an inner side perspective view of the embodiment of the pitch mechanism shown in FIG. 5A;

FIG. 6A is an outer side perspective view of another embodiment of a pitch mechanism having a bolted pitch lock;

FIG. 6B is an inner side perspective view of the embodiment of the pitch mechanism shown in FIG. 6A;

FIG. 7A is an outer side perspective view of another embodiment of a pitch mechanism having a hooked pitch lock;

FIG. 7B is an inner side perspective view of the embodiment of the pitch mechanism shown in FIG. 7A, attached to the front seat back by a bolting mechanism;

FIG. 7C is an outer side perspective view of the embodiment of the pitch mechanism shown in FIG. 7A, attached to the front seat back by a pin and groove mechanism;

FIG. 7D is an inner side perspective view of the embodiment of the pitch mechanism shown in FIG. 7C;

FIG. 8A is an outer side perspective view of another embodiment of a pitch mechanism having a locking joint; and

FIG. 8B is an inner side perspective view of the embodiment of the pitch mechanism shown in FIG. 8A.

DESCRIPTION

According to the present invention a compactable furniture system is provided. The furniture system is a “knock-down” seating system where the furniture can be manufactured remotely in unassembled pieces that can be shipped, stored, or moved in compact form and later assembled by the end user. The compactable furniture system has a pitch mechanism that allows the seat back to fold flat for shipping, storage, and moving. When the compactable furniture is assembled by the end user, the seat back is positioned for proper seating by inserting the pitch mechanism into place and locking, which adjusts the seat back to a desired pitch angle. The compactable furniture system according to the present invention allows approximately double the number of sofas to be shipped in a conventional shipping container, substantially lowering manufacturing costs. The compactable furniture system has the added advantage of having few detachable components for ease of assembly by the end user.

In one embodiment, the present invention is a compactable furniture system having a pitch mechanism. Referring to FIG. 1 and FIG. 2, there is shown a compactable furniture system 10 according to the present invention. FIG. 1 shows an unassembled compactable furniture system and FIG. 2 shows a partially assembled compactable furniture system comprising a seat back 12 having a front panel 14 and a rear panel 16. The front panel 14 and the rear panel 16 are pivotally connected at a front panel top end 18 and a rear panel top end 20. The front panel 14 and the rear panel 16 are removably connected at a front panel bottom end 22 and a rear panel bottom end 24 with a pitch mechanism 26 and 28. A first side support 30 and second side support 32 are attached to the seat back 12 and a front rail 34. A seat deck 36 is disposed between the seat back 12, the front rail 34, and the first and second side supports 30 and 32.

Referring again to FIG. 1, in one embodiment the furniture system 10 can additionally comprise support rails 38 and 40 (not shown) to support the seat deck 36. The furniture system 10 can additionally comprise a center bar 42 interposed between the rear panel 16 and the front rail 34 to further support the seat deck 36.

Referring to FIG. 3A and FIG. 3B, and referring again to FIG. 2, in another embodiment, the furniture system 10 additionally comprises a front seat deck lock 44, and a side seat deck lock 46 and 48 (not shown). As shown in FIG. 3A, an expanded front perspective view of the front seat deck lock 44, the front seat deck lock 44, has a front bracket 50 and a front plate 52 with a joining pin 54. As shown in FIG. 3A, the front bracket 50 is attached to the front rail 34. The joining pin 54 inserts into the front bracket 50. The front plate 52 rests on top of the front bracket 50 and can provide support for the seat deck 36. As shown in FIG. 3B, an expanded front perspective view of the side seat deck lock 46, the side seat deck lock 46, has a side bracket 56, a side plate 58, and a joining pin 60. The side bracket 56 attaches to the side support 30 and the joining pin 60 inserts into the side bracket 56. The side plate 60 rests on top of the side bracket 56 and can provide support for the seat deck 36. In a preferred, but not required embodiment, the seat deck 60 additionally can have a back stop 62. In another embodiment, the side plate 60 additionally can have an insert pin that inserts into the seat deck 36 to immobilize the seat deck 36, that is, to keep the seat deck 36 in a desired position when it is inserted in the compactable furniture system 10.

Referring again to FIG. 1, in a preferred, but not required embodiment, the compactable furniture system additionally comprises legs 64, 66, 68, and 70. As shown in FIG. 1, legs 64 and 66 are attached to the side support 30 and legs 68 and 70 are attached to the side support 32 by screws, as shown in FIG. 1, or can be attached by other attachment means as will be understood by those of skill in the art with reference to this disclosure. As also shown in FIG. 1, the legs 64, 66, 68, and 70 can be triangular shaped, or can have other leg shapes such as bun feet, turned legs, cylinders, squares, or can have other shapes as will be understood by those of skill in the art with reference to this disclosure. The legs can be manufactured from wood or other suitable material such as plastic and can be upholstered or not upholstered as also will be understood by those of skill in the art with reference to this disclosure.

Referring again to FIG. 1, the first side support 30 and the second side support 32 can be attached to the front rail 34 with an L bracket 72 and an L bracket 74 and bolts 76. The first side support 30 and the second side support 32 can be directly attached to the seat back 12 with bolts 78. Now referring to FIGS. 4A and 4B, and referring again to FIG. 2, in a preferred but not required embodiment, the first side support 30 and the second side support 32 can be attached to the front rail 34, with a hinge lock 80 and 90. FIG. 4A shows a front perspective view of the hinge lock 80, in an assembled form, and FIG. 4B shows a front perspective view of the hinge lock 80, in an unassembled form, according to the present invention. As shown in FIG. 4A, and FIG. 4B, the hinge lock 80 has a first hinge bracket 82 and a second hinge bracket 84. The first hinge bracket 82 and the second hinge bracket 84 are joined by inserting hinge pin 86 into the first and second hinge bracket 82 and 84. Optionally, hinge pin 86 can have a hinge plate 88 that can provide support for the seat deck 36 when the seat deck 36 is inserted in the compactable furniture system 10.

Now referring to FIG. 5A and FIG. 5B; FIGS. 6A and 6B; FIG. 7A, FIG. 7B, FIG. 7C, and FIG. 7D; and FIGS. 8A and 8B, variations of the pitch lock mechanism 26 according to the present invention are shown. As shown in FIG. 5A and FIG. 5B, in a preferred but not required embodiment, the pitch mechanism 26 is a slide lock 92. FIG. 5A is an outer side perspective view of the slide lock 92, and FIG. 5B, is an inner side perspective view of the slide lock 92 shown in FIG. 5A. The slide lock 92 is a slotted bracket 94 having one or more notches 96 and a pitch lock 98. As shown in FIG. 5B, the slide lock 92 is attached to the seat back 12 by attaching the front panel 14 to the end of the slide lock 92 when the pitch lock 98 is in an unextended position. A bolt 100 joins the slotted bracket 94 and the rear panel 16 of the seat back 12. As shown in FIG. 5A, the front panel 14 is then extended to a desired pitch angle and the slide lock 92 is straightened, thereby locking the pitch lock 98 in place. When more than one notch 96 is provided in the slide lock 92, the seat back can be adjustably locked in different positions.

Referring again to FIG. 6A and FIG. 6B, in another embodiment, the pitch mechanism 26 is a bolted pitch lock 102. FIG. 6A is an outer side perspective view of the bolted pitch lock 102, and FIG. 6B, is an inner side perspective view of the bolted pitch lock 102 shown in FIG. 6A. As shown in FIG. 6A and FIG. 6B, the bolted pitch lock 102 is a bar 104 having first and second apertures 106 and 108. The bolted pitch lock 102 is attached to the seat back 12 by attaching the rear panel 16 to the bolted pitch lock 102 through the first aperture 106 with a bolt 110. The front panel 14 is then extended and the bolted pitch lock 102 is attached to the front panel 14 through the second aperture 108 and a bolt 112, thereby locking the pitch mechanism 26 in place.

Referring again to FIG. 7A, in another embodiment, the pitch mechanism 26 is a hooked pitch lock 114. Figure A is an outer side perspective view of the hooked pitch lock 114, having a bar 116, an aperture 118, and a hook 120. One embodiment of the hooked pitch lock 114 is shown in FIG. 7B, an inner side perspective view of the hooked pitch lock 114 shown in FIG. 7A, where the hooked pitch lock 114 is attached to the seat back 12 by attaching the rear panel 16 to the hooked pitch lock 102 through the aperture 118 with a bolt 122. According to this embodiment, the front panel 14 of the seat back 12 is placed in an extended position and the hooked pitch lock 114 is attached to the front panel 14 by attaching the hook 120 to a bolt 124, thereby locking the pitch mechanism 26 in place. Another embodiment of the hooked pitch lock 114 is shown in FIG. 7C and FIG. 7D, an inner side perspective view, and an outer side perspective view, respectively, of the hooked pitch lock 114 shown in FIG. 7A. According to this embodiment, the front panel 14 of the seat back 12 is placed in an extended position and the hooked pitch lock 114 is attached to the front panel 14 by connecting the hook 120 to a pin 126 contained within a front panel groove 128, thereby locking the pitch mechanism 26 in place.

Referring again to FIG. 8A and FIG. 8B, in another embodiment, the pitch mechanism 26 is a locking joint 130. FIG. 8A is an outer side perspective view of the locking joint 130, and FIG. 8B, is an inner side perspective view of the locking joint 130 shown in FIG. 8A. As shown in FIG. 8A and FIG. 8B, the locking joint 130 is a bar 132 having first and second apertures 134 and 136 and a lock 138. The locking joint 130 is attached to the seat back 12 by attaching the front panel 14 and the rear panel 16 to the first and second apertures 134 and 136 of the locking joint 130. According to this embodiment, the front panel 14 is extended, rotating the lock 138, until the locking joint 130 is substantially straightened, thereby locking the pitch mechanism 26 in place.

Referring again to FIG. 2, the front panel 14 and the rear panel 16 are pivotally connected at a front panel top end 18 and a rear panel top end 20. In a preferred, but not required embodiment, the front panel 14 and the rear panel 16 are pivotally connected with one or more hinges 140, 142, and 144. However, the front panel 14 and the rear panel 16 are not necessarily connected with hardware such as a hinge and can be otherwise connected, or affixed, such as with fabric, cord, or plastic, or other suitable materials as will be understood by those of skill in the art with reference to this disclosure.

In another embodiment, the present invention is a method for assembling compactable furniture. In one embodiment, the method comprises selecting a furniture system according to the present invention. Then, the seat back 12 is attached to the first side support 30 and the second side support 32. Next, the front rail 34 is attached to the first side support 30 and the second side support 32. Next, the pitch mechanism 26 and 28 is inserted into the seat back 12 and the seat back 12 is locked at a pitch angle. Next, the seat deck 36 is inserted between the seat back 12, the front rail 34, and the first and second side supports 30 and 32.

In another embodiment, the method additionally comprises attaching a front seat deck lock 44 to the front rail 34, and attaching a side seat deck lock 46 and 48 to the first and second side supports 30 and 32, respectively. In another embodiment, the method additionally comprises attaching the first side support 30 and the second side support 32 to the front rail 34 with a hinge lock 80 and 90.

Although the present invention has been discussed in considerable detail with reference to certain preferred embodiments, other embodiments are possible. Therefore, the scope of the appended claims should not be limited to the description of preferred embodiments contained herein. 

1. A compactable furniture system comprising: a) a seat back having a front panel and a rear panel, wherein the front panel and the rear panel are: i) pivotally connected at a front panel top end and a rear panel top end; and ii) removably connected at a front panel bottom end and a rear panel bottom end; b) a pitch mechanism for removably connecting the front panel bottom end and the rear panel bottom end at a pitch angle; c) first and second side supports attached to the seat back; d) a front rail attached to the first and second side supports; and e) a seat deck disposed between the seat back, the front rail, and the first and second side supports.
 2. The furniture system of claim 1 additionally comprising a seat deck lock.
 3. The furniture system of claim 2 wherein the seat deck lock comprises a bracket and a plate having a joining pin.
 4. The furniture system of claim 1 additionally comprising a center bar interposed between the rear panel and the front rail.
 5. The furniture system of claim 1 additionally comprising a hinge lock.
 6. The furniture system of claim 5 wherein the hinge lock comprises first and second hinge plates and a hinge pin.
 7. The furniture system of claim 1 additionally comprising first and second legs attached to the first side support and third and fourth legs attached to the second side support.
 8. The furniture system of claim 1 wherein the pitch mechanism comprises a slotted bracket having one or more notches.
 9. The furniture system of claim 1 wherein the pitch mechanism comprises a bar with two apertures.
 10. The furniture system of claim 1 wherein the pitch mechanism comprises a bar with an aperture and a hook.
 11. The furniture system of claim 1 wherein the pitch mechanism comprises a locking joint.
 12. The furniture system of claim 1 wherein the front panel and the rear panel are pivotally connected with one or more hinges.
 13. A method for assembling compactable furniture comprising: a) selecting a furniture system according to claim 1; b) attaching the seat back to the first and second side supports; c) attaching the front rail to the first and second side supports; d) inserting the pitch mechanism and fixing the seat back at a pitch angle; and e) inserting the seat deck between the seat back, the front rail, and the first and second side supports.
 14. A method according to claim 13 wherein the furniture system additionally comprises a seat deck lock and the method additionally comprises attaching the seat deck lock to at least one of the first side support, the second side support or the front rail.
 15. A method according to claim 13 wherein the furniture system additionally comprises a hinge lock and the method additionally comprises attaching at least one of the first and second side supports to the front rail with a hinge lock. 